YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series REDUNDANCY MODULE Cost Effective Solution to Build Redundant Systems Dual Input with Single Output Two Diodes (Common Cathode) DC12-48V (120V) ±25% Wide-range Input Full Power Between -40°C and +60°C Width only 32mm Rugged Metal Housing Quick-connect Spring-clamp Terminals Easy Wiring: Distribution Terminal for Negative Pole Included 3 Year Warranty GENERAL DESCRIPTION SHORT-FORM DATA The YR2.DIODE is a redundancy module, which can be used to build 1+1 and N+1 redundant systems. It is equipped with two input channels, which can be connected to power supplies with up to 10A output current and one output, which can carry nominal currents up to 20A. The module is suitable for power supplies with constant current overload behavior as well as any kind of “Hiccup” overload behavior. Input voltage The YR2.DIODE is the perfect solution to use in a redundant system, if the power supply itself is equipped with a DC-OK signal (e.g.: DIMENSION Q-Series). In addition to the YR2.DIODE is the YRM2.DIODE which has a monitoring circuitry included. LEDs and relay contacts signal when one of the two DC-input voltages is not in range due to a non-functioning power supply. Another interesting application for this diode module is to separate sensitive loads from non-sensitive loads. This avoids the distortion of the power quality for the sensitive loads which can cause controller failures. Unique quick-connect spring-clamp terminals allow a safe and fast installation and a large international approval package for a variety of applications makes this unit suitable for nearly every situation. ORDER NUMBERS Input voltage range Input current Output current DC 12-48V ±25% DC 12-120V ±25% 9-60Vdc 9-150Vdc 2x 0-10A 2x 0-16A 0-20A 20-32A 25A Input to output voltage drop typ. 0.78V typ. 0.85V typ. 0.85V Power losses typ. 0W typ. 7.8W typ. 8.5W typ. 17W Temperature range -40°C to +70°C Derating 0.5A/°C Dimensions 32x124x102mm MARKINGS Redundancy Module YR2.DIODE 12-48V (120V) Standard unit Accessory ZM1.WALL Wall/ panel mount bracket Side mount bracket IND. CONT. EQ. ZM11.SIDE w/o restrictions with restrictions w/o restrictions with restrictions continuous for 5 seconds continuous for 5 seconds at cont. overload/ short circuit input: 2x5A input: 1x10A input: 2x10A at no load input: 2x5A input: 1x10A input: 2x10A operational, +60 to +70°C WxHxD UL 508 UL 60950-1 IECEx ATEX II 3G Ex nA IIC T4 Gc Marine Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany Class I Div 2 EMC, LVD 1/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series INDEX Page 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Intended Use .......................................................3 Installation Requirements...................................3 Input and Output Characteristics .......................4 Power Losses........................................................5 Lifetime Expectancy and MTBF...........................6 Terminals and Wiring..........................................7 Functional Diagram.............................................8 Front Side and User Elements.............................8 EMC......................................................................9 Environment ......................................................10 Protection Features ...........................................11 Safety Features ..................................................11 Dielectric Strength ............................................11 Approvals...........................................................12 Page 15. Physical Dimensions and Weight ..................... 13 16. Accessories ........................................................ 14 17. Application Notes............................................. 15 17.1. Recommendations for Redundancy.........15 17.2. Inductive and Capacitive Loads................15 17.3. Example: 1+1 Redundancy up to 10A......15 17.4. Example: N+1 Redundancy up to 30A .....16 17.5. Example: Battery Back-up ........................16 17.6. Example: Redundancy for Controls .........17 17.7. Example: Decoupling of Branches ...........18 17.8. Use in a Tightly Sealed Enclosure ............18 17.9. Mounting Orientations ............................19 The information presented in this document is believed to be accurate and reliable and may change without notice. No part of this document may be reproduced or utilized in any form without permission in writing from the publisher. TERMINOLOGY AND ABREVIATIONS PE and symbol PE is the abbreviation for Protective Earth and has the same meaning as the symbol . Earth, Ground This document uses the term “earth” which is the same as the U.S. term “ground”. T.b.d. To be defined, value or description will follow later. DC 24V A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually ±15%) included. E.g.: DC 12V describes a 12V battery disregarding whether it is full (13.7V) or flat (10V) 24Vdc A figure with the unit (Vdc) at the end is a momentary figure without any additional tolerances included. A key word indicating a mandatory requirement should A key word indicating flexibility of choice with a strongly preferred implementation 1+1 Redundancy Use of two identical power supplies in parallel to provide continued operation following most failures in a single power supply. The two N+1 1+1 Redundancy Redundancy power supply outputs should be isolated AC AC AC AC AC AC AC AC from each other by utilizing diodes or other switching arrangements. DC DC DC DC DC DC DC DC E.g. two 10A power supplies are needed to achieve a 10A redundant system. IN 1 IN 2 IN 1 IN 2 IN 1 IN 2 IN 1 IN 2 N+1 Redundancy Use of three or more identical power supplies in parallel to provide continued OUT OUT OUT OUT operation following most failures in a single power supply. All power supply Load Load outputs should be isolated from each other by utilizing diodes or other switching arrangements. E.g.: To achieve a 40A redundant system, five 10A power supplies are needed in a N+1 redundant system. Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany + A key word indicating flexibility of choice with no implied preference + may shall 2/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 1. INTENDED USE This redundancy module is designed for installation in an enclosure and is intended for the general use such as in industrial control, office, communication, and instrumentation equipment. This redundancy module can be used with any type of power supply as long as the maximum ratings are not exceeded. It is suitable for power supplies with constant current overload behavior as well as any kind of “Hiccup” overload behavior. Do not use this redundancy module in equipment, where malfunction may cause severe personal injury or threaten human life. This device is designed for use in hazardous, non-hazardous, ordinary or unclassified locations. 2. INSTALLATION REQUIREMENTS This device may only be installed and put into operation by qualified personnel. This device does not contain serviceable parts. If damage or malfunction should occur during installation or operation, immediately turn power off and send unit to the factory for inspection. Mount the unit on a DIN-rail so that the input terminals are located on the top and the output terminals on the bottom of the unit. For other mounting orientations see de-rating requirements of chapter 17.9. in this document. This device is designed for convection cooling and does not require an external fan. Do not obstruct airflow and do not cover the ventilation grid (e.g. cable conduits) by more than 30%! Keep the following installation clearances: 40mm on top, 20mm on the bottom, 5mm on the left and right sides are recommended when the device is loaded permanently with more than 50% of the rated output current. Increase the side clearance to 15mm in case the adjacent device is a heat source (e.g. another power supply). WARNING - Risk of electrical shock, fire, personal injury or death. Turn power off before working on the device. Protect against inadvertent re-powering. Make sure that the wiring is correct by following all local and national codes. Do not open, modify or repair the unit. Use caution to prevent any foreign objects from entering the housing. Do not use in wet locations or in areas where moisture or condensation can be expected. Do not touch during power-on, and immediately after power-off. Hot surfaces may cause burns. Notes for use in hazardous location areas: The redundancy module is suitable for use in Class I Division 2 Groups A, B, C, D locations and for use in Group II Category 3 (Zone 2) environments and is evaluated according to EN 60079-0:2009 and EN 60079-15:2010. WARNING EXPLOSION HAZARDS! Substitution of components may impair suitability for this environment. Do not disconnect the unit unless power has been switched off or the area is known to be non-hazardous. A suitable enclosure must be provided for the end product which has a minimum protection of IP54 and fulfils the requirements of the EN 60079-15:2010. Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 3/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 3. INPUT AND OUTPUT CHARACTERISTICS Number of inputs Number of outputs Input voltage nom. 2 1 DC 12-48V ±25% Input voltage range Input voltage with restrictions Input voltage range with restrictions Voltage drop, input to output nom. - 9-60Vdc DC 12-120V ±25% 9-150Vdc See note 3 on bottom of the table Restrictions apply, see note 3 on bottom of the table. typ. typ. typ. nom. nom. nom. max. nom. nom. max. max. max. 0.78V 0.85V 0.85V 2x 0-10A 1x 0-20A 2x 10-16A 150A 20A 20-32A 25A 2mA 200Vdc at 2x5A, see Fig. 3-2 at 1x10A, see Fig. 3-3 at 2x10A, see Fig. 3-2 continuous continuous, see note 1 for 5 seconds for maximal 10ms per input continuous for 5 seconds at continuous overload or short circuit, see note 2 per input, -40°C to +60°C voltage applied to the output, continuously allowed Input current Peak input current Output current Reverse current Reverse voltage Note 1: Note 2: Note 3: The input circuitry must meet the SELV requirements stipulated by IEC/EN/UL 60950-1. Each input can be loaded up to 20A. At currents above 10A, the other input should not be loaded. It is preferable to parallel the two inputs in order to minimize the power loss in such cases. Ensure that the continuous output current does not exceed 25A. Check the short-circuit current of the power sources and if the power source can deliver more than 25A together, use an appropriate fuse on the output. The redundancy module can be used with input voltages up to 150Vdc with the constraint, that it can be used only as a single input module at voltages above 60Vdc. Both inputs need to be connected together as shown in Fig. 3-1. Ensure proper means to protect against touching this voltage. Fig. 3-1 Restrictions for utilizing voltages between 60 and 150Vdc (See also Note 3) Power Supply Power Supply + DC (>60V) Power Supply Diode Module + + - - + - AC + DC (>60V) + Load - Diode Module + + + - - - + AC AC DC (>60V) - + Load - >60V Power Supply + + + - - - + AC DC (>60V) >60V Diode Module - Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 4/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series Fig. 3-2 Input to output voltage drop when both inputs draw current (typical 1+1 redundant case, when the output voltages of the two units are equal or set into “parallel use” mode) Voltage Drop, typ. QS/QT10 1000mV I1 A 24V,10A + 800mV A V U1 B A... 25°C B... 60°C 400mV QS/QT10 + Input, Output Current 5A 2x2.5A 10A 2x5A Output Variable Load, 0-20A UOUT V I2 A 24V,10A 200mV 0mV Input 1 IOUT A - 600mV Output: 0 Input: 0 Output YR2 / YRM2 15A 20A 2x7.5A 2x10A V U2 Input 2 I1 = I2 U1 = U2 Voltage Drop = U1 - UOUT Fig. 3-3 Input to output voltage drop when only one input draws current QS/QT20 Voltage Drop, typ. I1 A 24V,20A 1000mV + 800mV A V U1 Output YR2 / YRM2 Input 1 IOUT A Output Variable Load, 0-20A UOUT V - B 600mV A... 25°C B... 60°C 400mV 200mV Output Current 0mV 0 5A 10A 15A Not used or power supply with lower voltage Input 2 20A Voltage Drop = U1 - UOUT 4. POWER LOSSES Power losses DC 24V 7.8W 8.5W 17.0W 0W typ. typ. typ. typ. Standby power losses input: 2x5A input: 1x10A input: 2x10A at no output current Fig. 4-1 Power losses Power Losses, typ. 24W 20 16 12 8 4 Output Current 0 0 5 10 15 20 25A Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 5/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 5. LIFETIME EXPECTANCY AND MTBF The redundancy module has two input channels which are completely independent from each other. Each control circuit, auxiliary voltage source, or other circuitry in the module are designed separately for each input. The dual input redundancy module can be considered as two single redundancy modules combined together in one housing. The only common point is the circuit trace that ties the two separate circuits together at the output. The MTBF figures below are for the entire dual input module. If the MTBF number of only one path is needed, simply double the value from the table. The redundancy module does not have electrolytic capacitors included. Therefore, the lifetime expectancy is extremely high. Input / output current conditions Lifetime expectancy *) MTBF **) SN 29500, IEC 61709 MTBF **) MIL HDBK 217F min. min. Input: 2x10A Output: 20A 25 years 25 years 46 500 000h 70 000 000h 36 200 000h 41 100 000h Input: 2x5A Output: 10A 25 years 25 years 55 700 000h 84 000 000h 43 500 000h 49 300 000h at 24V and 40°C at 24V and 25°C at 24V 40°C at 24V 25°C at 24Vand 40°C (Ground Benign GB40) at 24Vand 25°C (Ground Benign GB25) *) The Lifetime expectancy shown in the table indicates the minimum operating hours (service life). **) MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates reliability of a device. It is the statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product. The MTBF figure is a statistical representation of the likelihood of a device to fail. A MTBF figure of e.g. 1 000 000h means that statistically one unit will fail every 100 hours if 10 000 units are installed in the field. However, it can not be determined if the failed unit has been running for 50 000h or only for 100h. Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 6/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 6. TERMINALS AND WIRING Type Solid wire Stranded wire American Wire Gauge Max. wire diameter Wire stripping length Pull-out force Input and output Bi-stable, quick-connect spring clamp terminals. IP20 Finger safe construction. Suitable for field- and factory installation. Shipped in open position. 0.5-6mm2 0.5-4mm2 20-10 AWG 2.8mm (including ferrule) 10mm / 0.4inch 10AWG:80N, 12AWG:60N, 14AWG:50N, 16AWG:40N (according to UL486E) Instructions: a) Use appropriate copper cables that are designed for minimum operating temperatures of: 60°C for ambient up to 45°C and 75°C for ambient up to 60°C and 90°C for ambient up to 70°C minimum. b) Follow national installation codes and installation regulations! c) Ensure that all strands of a stranded wire enter the terminal connection! d) Ferrules are allowed. e) Do not connect or disconnect the wires from the terminals below -25°C (-13°F). Fig. 6-1 Connecting a wire 1. Insert the wire 2. Snap the lever To disconnect wire: same procedure vice versa Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 7/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 7. FUNCTIONAL DIAGRAM Fig. 7-1 Functional diagram Input 1 + - + Input 2 - + - Output Chassis Ground 8. FRONT SIDE AND USER ELEMENTS Fig. 8-1 Front side A Output terminals B Chassis ground terminal Connection of the chassis to ground is optional and not required since the unit fulfils the requirements according to protection class III. C Input terminals for input 1 D Input terminals for input 2 Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 8/19 YR2.DIODE Y-Series DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE 9. EMC The redundancy module is suitable for applications in industrial environment as well as in residential, commercial and light industry environment without any restrictions. A detailed EMC report is available on request. EMC Immunity Electrostatic discharge Electromagnetic RF field Fast transients (Burst) Surge voltage on input lines Surge voltage on output lines Conducted disturbance Power-frequency magnetic field *) According generic standards: EN 61000-6-1 and EN 61000-6-2 EN 61000-4-2 Contact discharge 8kV Air discharge 15kV EN 61000-4-3 80MHz-2.7GHz 10V/m EN 61000-4-4 Input lines 2kV Output lines 2kV EN 61000-4-5 1kV +/- Æ Chassis ground EN 61000-4-5 1kV +/- Æ Chassis ground EN 61000-4-6 0.15-80MHz 10V EN 61000-4-8 50Hz 30A/m Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterion A Criterions: A: Redundancy module shows normal operation behavior within the defined limits. Notes: *) A test is not applicable according to EN 61000-6-2, since the device does not contain components susceptible to magnetic fields, e.g. hall elements, electrodynamic microphones, etc. According generic standards: EN 61000-6-3 and EN 61000-6-4 IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 Class B, input lines *) IEC/CISPR 16-1-2, IEC/CISPR 16-2-1 Class B, output lines *) Radiated emission EN 55011, EN 55022 Class B This device complies with FCC Part 15 rules. Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. EMC Emission Conducted emission *) Provided, that power sources connected on the inputs fulfill the class B requirements too. Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 9/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 10. ENVIRONMENT Operational temperature *) Output de-rating Storage temperature Humidity **) Vibration sinusoidal ***) Shock ***) Altitude -40°C to +70°C (-40°F to 158°F) 0.5A/°C -40 to +85°C (-40°F to 185°F) 5 to 95% r.H. 2-17.8Hz: ±1.6mm 17.8-500Hz: g 2 hours / axis 30g 6ms, 20g 11ms 3 bumps / direction 18 bumps in total 0 to 2000m (0 to 6 560ft) 2000 to 6000m (6 560 to 20 000ft) Reduce output power above +60°C 60-70°C (140°F to 158°F), see for storage and transportation IEC 60068-2-30 IEC 60068-2-6 IEC 60068-2-27 without any restrictions reduce output power or ambient temperature, see Fig. 10-2 1.25A/1000m or 5°C/1000m > 2000m (6500ft), see Fig. 10-2 not applicable The concept of the overvoltage category is used for equipment energized directly from the low voltage mains (IEC 60664-1 §4.3.3.2.1). 2 IEC 62103, EN 50178, not conductive The unit does not release any silicone or other LABS-critical substances and is suitable for use in paint shops. Altitude de-rating Over-voltage category Degree of pollution LABS compatibility *) Operational temperature is the same as the ambient temperature and is defined as the air temperature 2cm below the unit. **) Do not energize while condensation is present ***) Tested in combination with DIN-Rails according to EN 60715 with a height of 15mm and a thickness of 1.3mm and standard mounting orientation. Fig. 10-1 Output current vs. ambient temp. Allowed Output Current 30A 25 Fig. 10-2 Output current vs. altitude Allowed Output Current 30A at overload / short circuit 20 normal mode 15 10 10 5 5 Ambient Temperature 0 20 normal mode 20 15 0 -40 -25 overload / short circuit 25 40 A A... Tamb < 60°C B... Tamb < 50°C C... Tamb < 40°C 0 2000 C Altitude 0 60 70°C B 4000 6000m Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 10/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 11. PROTECTION FEATURES Output over-current protection Reverse input polarity protection Degree of protection Penetration protection Over-temperature protection Input transient protection Output transient protection Internal input fuse not included included IP 20 > 3.6mm not included not included included not included unit does not start when input voltage is reversed EN/IEC 60529 e.g. screws, small parts see EMC section 12. SAFETY FEATURES Input / output separation Safety level of output voltage Class of protection PE resistance no galvanic separation 200V epitaxial diode between input and output The output voltage is regarded to be SELV (EN 60950-1) or PELV (EN 60204-1, EN 50178, IEC 60364-4-41) if the input voltage fulfills the requirements for a SELV source or PELV source. III PE (Protective Earth) or chassis connection not required < 0.1Ohm between housing and chassis-ground terminal 13. DIELECTRIC STRENGTH The input and output voltages have the same reference, are floating and have no ohmic connection to ground. Type and factory tests are conducted by the manufacturer. Field tests may be conducted in the field using the appropriate test equipment which applies the voltage with a slow ramp (2s up and 2s down). Connect input/output terminals together before conducting the test. When testing, set the cut-off current settings to the value in the table below. Fig. 13-1 Dielectric strength Type test In- / Output + - Chassis A 60s A 500Vac Factory test 5s 500Vac Field test 5s 500Vac Cut-off current setting > 2mA Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 11/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 14. APPROVALS The CE mark indicates conformance with the - EMC directive 2004/108/EC, - Low-voltage directive (LVD) 2006/95/EC and - RoHS directive 2011/65/EU. The CE mark indicates conformance with the - ATEX directive 94/9/EC (Equipment and protection systems intended for use in potentially explosive atmospheres) CB Scheme, Information Technology Equipment EC Declaration of Conformity EC Declaration of Conformity ATEX IEC 60950-1 UL 508 IND. CONT. EQ. UL 60950-1 CSA 22.2 No107.1-01 HazLoc (Class 1 Div 2) ANSI / ISA 12.12.01-2007 ATEX EN 60079-0, EN 60079-15 II 3G Ex nA IIC T4 Gc IECEx IEC 60079-0, IEC 60079-15 Marine GOST R IECEx Ex nA IIC T4 Gc Listed for use as Industrial Control Equipment; U.S.A. (UL 508) and Canada (C22.2 No. 107-1-01); E-File: E198865 Recognized for use as Information Technology Equipment, Level 5; U.S.A. (UL 60950-1) and Canada (C22.2 No. 60950); E-File: E137006 CSA approval for Canada CAN/CSA C22.2 No 107-1; CAN/ CSA 60950-1-03; UL60950-1 LISTED for use in Hazardous Location Class I Div 2 T4 Groups A,B,C,D systems; U.S.A. (ANSI / ISA 12.12.01-2007) and Canada (C22.2 No. 213-M1987) Suitable for use in Category 3 Zone 2 locations. Number of ATEX certificate: EPS 11 ATEX 1 312 X The redundancy module must be built-in in an IP54 enclosure. Suitable for use in Category 3 Zone 2 locations. Number of IECEx certificate: IECEx EPS 12.0032X GL (Germanischer Lloyd) classified and ABS (American Bureau for Shipping) PDA, Environmental category: C, EMC2, Marine and offshore applications Certificate of Conformity for Russia and other GUS countries Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 12/19 YR2.DIODE Y-Series DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE 15. PHYSICAL DIMENSIONS AND WEIGHT Weight DIN-Rail Installation clearances 290g / 0.64lb Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm. The DIN-rail height must be added to the unit depth (102mm) to calculate the total required installation depth. See chapter 2 Fig. 15-1 Front view Fig. 15-2 Side view Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 13/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 16. ACCESSORIES ZM1.WALL Wall mounting bracket This standard bracket is used to mount the YR40 redundancy module onto a flat surface without utilizing a DIN-Rail. Fig. 16-1 ZM1.WALL Wall mounting bracket Fig. 16-2 Assembled wall mounting bracket ZM11.SIDE Side mounting bracket This bracket is used to mount the YR80 redundancy module sideways with or without utilizing a DIN-Rail. The two aluminum brackets and the black plastic slider of the unit have to be detached, so that the steel brackets can be mounted. For sideway DIN-rail mounting, the removed aluminum brackets and the black plastic slider need to be mounted on the steel bracket. Fig. 16-3 ZM11.SIDE Side mounting bracket Fig. 16-4 Side mounting with DIN-rail brackets Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 14/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 17. APPLICATION NOTES 17.1. RECOMMENDATIONS FOR REDUNDANCY Recommendations for the configuration of redundant power systems: • Use separate input fuses for each power supply. • Use three-phase power supplies to gain functional safety if one phase fails. • When single-phase power supplies are utilized connect them to different phases or mains circuits if possible. • Set the power supply in “Parallel-Use” mode if this feature is available • It is desirable to set the output voltages of all power supplies to the same value. 17.2. INDUCTIVE AND CAPACITIVE LOADS The unit is designed to supply any kind of loads, including unlimited capacitive and inductive loads. 17.3. EXAMPLE: 1+1 REDUNDANCY UP TO 10A 1+1 Redundancy up to 10A requires two 10A power supplies and one YR2.DIODE redundancy module. Fig. 17-1 Wiring diagram, 1+1 Redundancy, 10A output current Failure Monitor ++ -- 24V,10A Adj DCok Overload QS10.241 Power Supply L N PE +- +- IN 1 IN 2 YR2.Diode Redundancy Module ++ -- 24V,10A Adj DCok Overload QS10.241 Power Supply OUT L N PE + - optional I I 10A Load L N PE Note: Use separate mains systems for each power supply whenever it is possible Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 15/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 17.4. EXAMPLE: N+1 REDUNDANCY UP TO 30A N+1 Redundancy up to 30A requires four 10A power supplies and two YR2.DIODE redundancy modules. Fig. 17-2 Wiring diagram, n+1 Redundancy, 30A output current Failure Monitor ++ -- 24V,10A Adj DCok Overload QS10.241 Power Supply L N PE +- +- IN 1 IN 2 YR2.Diode Redundancy Module ++ -- ++ 24V,10A Adj DCok Overload QS10.241 Power Supply QS10.241 Power Supply OUT L N PE + - I -- 24V,10A Adj DCok Overload +- +- IN 1 IN 2 YR2.Diode Redundancy Module L N PE + - I -- QS10.241 Power Supply OUT L N PE I ++ 24V,10A Adj DCok Overload I L N PE optional 30A Load Note: Use separate mains systems for each power supply whenever it is possible 17.5. EXAMPLE: BATTERY BACK-UP A battery back-up with 10A requires one 10A power supply and one YR2.DIODE redundancy module. Please note: Set output voltage of power supply to 26.5Vdc minimum to ensure, that the load current is delivered from the power supply and not from charger (battery). Use a fuse between battery and YR2.DIODE! Fig. 17-3 Wiring diagram, 10A Battery back-up Failure Monitor I + 24V Battery ++ -- +- +- IN 1 IN 2 24V,10A Adj DCok Overload Battery Charger QS10.241 Power Supply YR2.Diode Redundancy Module OUT L N PE L N PE + - optional 10A Load Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 16/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 17.6. EXAMPLE: REDUNDANCY FOR CONTROLS The example shows a cost effective solution to get redundant power for a PLC or controller system. In many cases, two power supplies are used; one for the demanding loads and another one for the controls and sensitive loads. The power supply for the demanding loads can be used as a redundant source to supply the controls. Traditional approach: Improved approach: PS1 Load PS2 PLC PS1 Load YR2 PS2 PLC Fig. 17-4 Wiring diagram, redundancy for sensitive loads Failure Monitor Heavy Loads e.g. Motors -- ++ +- +- IN 1 IN 2 24V,20A Adj DCok Overload QT20.241 Power Supply YR2.Diode Redundancy Module OUT L1 L2 L3 PE I L1 L2 L3 N PE I + - ++ -- 24V, 5A Adj DCok Overload QS5.241 Power Supply L N PE I optional Sensitive Load e.g. Controller I Note: Use separate mains systems for each power supply whenever it is possible Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 17/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 17.7. EXAMPLE: DECOUPLING OF BRANCHES Buffer energy supplied from a DC-UPS or buffer module is not wasted in “power branches”. Please note: Set output voltage of the power supply to a level that the buffer unit or DC-UPS will not start unexpected. Take the voltage drop of the YR2.DIODE into account. Fig. 17-5 Wiring diagram, decoupling of buffered branches Failure Monitor Load e.g. Motor -- ++ 24V,20A Adj DCok Overload QT20.241 Power Supply L1 L2 L3 PE +- +- IN 1 IN 2 YR2.Diode Redundancy Module OUT Buffer Module + - + - I I Buffered Load e.g. Controller I L1 L2 L3 PE optional Note: Use separate mains systems for each power supply whenever it is possible 17.8. USE IN A TIGHTLY SEALED ENCLOSURE When the redundancy module is installed in a tightly sealed enclosure, the temperature inside the enclosure will be higher than outside. The inside temperature defines the ambient temperature for the redundancy module. Results from such an installation: Power supply is placed in the middle of the box, no other heat producer inside the box Enclosure: Load: Input: Temperature inside enclosure: Temperature outside enclosure: Temperature rise: Rittal Typ IP66 Box PK 9516 100, plastic, 110x180x165mm 24V, 16A; (=80%) load is placed outside the box 24Vdc 57.8°C (in the middle of the right side of the power supply with a distance of 2cm) 24.6°C 33.2K Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 18/19 YR2.DIODE DC12-48V (120V), 20A, DUAL REDUNDANCY MODULE Y-Series 17.9. MOUNTING ORIENTATIONS Mounting orientations other than input terminals on the bottom and output on the top require a reduction in continuous output power or a limitation in the maximum allowed ambient temperature. Fig. 17-6 Mounting Orientation A (Standard orientation) Output Current INPUT 20A 16 12 8 4 0 10 Redundancy Module OUTPUT Fig. 17-7 Mounting Orientation B (Upside down) 20 30 40 50 60°C Output Current OUTPUT 20A 16 12 8 4 0 10 Redundancy Module INPUT Fig. 17-8 Mounting Orientation C (Table-top mounting) Ambient Temperature 20 30 40 50 60°C Output Current 20A 16 12 8 4 0 10 Ambient Temperature 20 30 40 50 60°C Output Current INPUT Fig. 17-10 Mounting Orientation E (Horizontal ccw) Redundancy Module OUTPUT 20A 16 12 8 4 0 10 Ambient Temperature 20 30 40 50 60°C OUTPUT INPUT Output Current Redundancy Module Fig. 17-9 Mounting Orientation D (Horizontal cw) Ambient Temperature 20A 16 12 8 4 0 10 Ambient Temperature 20 30 40 50 60°C Apr. 2014 / Rev. 1.4 DS-YR2.DIODE-EN All parameters are specified at 24V, 20A output current, 25°C ambient and after a 5 minutes run-in time unless otherwise noted www.pulspower.com Phone +49 89 9278 0 Germany 19/19
